EP3401955A1 - Plug-in connector with a cooling jacket - Google Patents
Plug-in connector with a cooling jacket Download PDFInfo
- Publication number
- EP3401955A1 EP3401955A1 EP17170805.0A EP17170805A EP3401955A1 EP 3401955 A1 EP3401955 A1 EP 3401955A1 EP 17170805 A EP17170805 A EP 17170805A EP 3401955 A1 EP3401955 A1 EP 3401955A1
- Authority
- EP
- European Patent Office
- Prior art keywords
- cooling jacket
- connector
- plug
- coolant
- contact element
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Granted
Links
- 238000001816 cooling Methods 0.000 title claims abstract description 275
- 239000012530 fluid Substances 0.000 claims abstract description 151
- 239000000463 material Substances 0.000 claims abstract description 24
- 239000002826 coolant Substances 0.000 claims description 127
- 229920001971 elastomer Polymers 0.000 claims description 18
- 239000000806 elastomer Substances 0.000 claims description 18
- 238000000034 method Methods 0.000 claims description 16
- 238000009413 insulation Methods 0.000 description 18
- 230000013011 mating Effects 0.000 description 13
- 238000007789 sealing Methods 0.000 description 13
- 238000002788 crimping Methods 0.000 description 10
- 239000004020 conductor Substances 0.000 description 9
- 238000003825 pressing Methods 0.000 description 8
- 125000006850 spacer group Chemical group 0.000 description 8
- 230000009477 glass transition Effects 0.000 description 6
- 238000005304 joining Methods 0.000 description 6
- 239000012809 cooling fluid Substances 0.000 description 5
- 239000002184 metal Substances 0.000 description 5
- 238000003466 welding Methods 0.000 description 5
- 229920000459 Nitrile rubber Polymers 0.000 description 4
- 230000008878 coupling Effects 0.000 description 3
- 238000010168 coupling process Methods 0.000 description 3
- 238000005859 coupling reaction Methods 0.000 description 3
- 238000010292 electrical insulation Methods 0.000 description 3
- 229920001084 poly(chloroprene) Polymers 0.000 description 3
- 229920001973 fluoroelastomer Polymers 0.000 description 2
- 230000003993 interaction Effects 0.000 description 2
- 239000004033 plastic Substances 0.000 description 2
- 229920003023 plastic Polymers 0.000 description 2
- 229920000642 polymer Polymers 0.000 description 2
- 230000001681 protective effect Effects 0.000 description 2
- 229920002379 silicone rubber Polymers 0.000 description 2
- 239000004945 silicone rubber Substances 0.000 description 2
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 2
- 244000043261 Hevea brasiliensis Species 0.000 description 1
- 230000008901 benefit Effects 0.000 description 1
- 230000005540 biological transmission Effects 0.000 description 1
- 230000001419 dependent effect Effects 0.000 description 1
- 238000007599 discharging Methods 0.000 description 1
- 239000013013 elastic material Substances 0.000 description 1
- 239000007788 liquid Substances 0.000 description 1
- 238000004519 manufacturing process Methods 0.000 description 1
- 229920003052 natural elastomer Polymers 0.000 description 1
- 229920001194 natural rubber Polymers 0.000 description 1
- 230000037361 pathway Effects 0.000 description 1
- 229920003051 synthetic elastomer Polymers 0.000 description 1
- 239000005061 synthetic rubber Substances 0.000 description 1
Images
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60L—PROPULSION OF ELECTRICALLY-PROPELLED VEHICLES; SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL; MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES
- B60L53/00—Methods of charging batteries, specially adapted for electric vehicles; Charging stations or on-board charging equipment therefor; Exchange of energy storage elements in electric vehicles
- B60L53/10—Methods of charging batteries, specially adapted for electric vehicles; Charging stations or on-board charging equipment therefor; Exchange of energy storage elements in electric vehicles characterised by the energy transfer between the charging station and the vehicle
- B60L53/14—Conductive energy transfer
- B60L53/16—Connectors, e.g. plugs or sockets, specially adapted for charging electric vehicles
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60L—PROPULSION OF ELECTRICALLY-PROPELLED VEHICLES; SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL; MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES
- B60L53/00—Methods of charging batteries, specially adapted for electric vehicles; Charging stations or on-board charging equipment therefor; Exchange of energy storage elements in electric vehicles
- B60L53/30—Constructional details of charging stations
- B60L53/302—Cooling of charging equipment
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
- H01R13/02—Contact members
- H01R13/10—Sockets for co-operation with pins or blades
- H01R13/11—Resilient sockets
- H01R13/111—Resilient sockets co-operating with pins having a circular transverse section
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R2201/00—Connectors or connections adapted for particular applications
- H01R2201/26—Connectors or connections adapted for particular applications for vehicles
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
- Y02T10/00—Road transport of goods or passengers
- Y02T10/60—Other road transportation technologies with climate change mitigation effect
- Y02T10/70—Energy storage systems for electromobility, e.g. batteries
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
- Y02T10/00—Road transport of goods or passengers
- Y02T10/60—Other road transportation technologies with climate change mitigation effect
- Y02T10/7072—Electromobility specific charging systems or methods for batteries, ultracapacitors, supercapacitors or double-layer capacitors
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
- Y02T90/00—Enabling technologies or technologies with a potential or indirect contribution to GHG emissions mitigation
- Y02T90/10—Technologies relating to charging of electric vehicles
- Y02T90/12—Electric charging stations
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
- Y02T90/00—Enabling technologies or technologies with a potential or indirect contribution to GHG emissions mitigation
- Y02T90/10—Technologies relating to charging of electric vehicles
- Y02T90/14—Plug-in electric vehicles
Definitions
- the invention relates to a plug-in connector.
- the invention further relates to a method for operating a plug-in connector.
- US Patent US 9 321 362 B2 and US Patent Applications US 2015/0217654 A1 and US 2016/0200206 A1 relate to cooling of a charging cable.
- a charging system for an electric vehicle including a power supply, a cable having first and second ends, the first end attached to the power supply, with the cable comprising a charging conductor and a cooling conduit, each of which extends from the first end to the second end.
- the charging system further comprises a connector attached to the second end of the cable, the connector having a form factor corresponding to a charge port of the electric vehicle.
- the cooling conduit is adapted to convey a fluid that cools the charging conductor.
- German Patent Application DE 10 2015 100 347 A1 describes an electrical connecting element for a charging connector and/or a charge port and to a charging connector and a charging station for supplying electrical energy to a recipient.
- An electrical connecting element for a charging connector and/or a charge port is described, wherein the electrical connecting element comprises a first connecting zone for a galvanic connection with an electrical power recipient and a second connecting zone for a galvanic connection with an electric power source, with the electrical connecting element comprising a cooling fluid channel that is formed in the electrical connecting element.
- a charging connector for coupling with a corresponding coupling apparatus and for transmission of electrical energy is disclosed, wherein the charging connector comprises an electrical connecting element, with the cooling fluid channel of the electrical connecting element being fluidically connected with a source of cooling fluid.
- a charging station for supplying electrical energy to a recipient is disclosed, wherein the charging station comprises a charging connector and a source of cooling fluid that is fluidically connectable with a cooling fluid channel of the electrical connecting element.
- the object of the invention is to provide a plug-in connector with a cooling facility that allows to effectively discharge heat.
- a plug-in connector comprises a contact element with a connector element and at least one terminal connector and a cooling jacket with a first fluid port adapted for fluidically connecting the cooling jacket with a first tube and a second fluid port adapted for fluidically connecting the cooling jacket with a second tube.
- the cooling jacket further comprises a connecting sleeve for accommodating the contact element, wherein the cooling jacket is manufactured in one piece and wherein the cooling jacket is made of a polymeric material.
- An outer surface of the contact element is encompassed by the connecting sleeve in a fluid-tight manner, wherein the connector element is at least partly exposed to the outside of the cooling jacket and wherein the at least one terminal connector is at least partly disposed in the interior of the cooling jacket.
- the at least one terminal connector is configured for being electrically connected with at least one electrical wire that is introducible into the cooling jacket via at least one of the fluid ports.
- the contact element is made of an electrically conductive material, preferably of metal.
- the contact element comprises a connector element that is at least partly exposed to the outside of the cooling jacket.
- the connector element may for example be configured for electrically contacting a contact element of a mating connector or for being plugged into a mating connector.
- the connector element may be implemented as a connector plug or a connector socket.
- the contact element further comprises at least one terminal connector, with the at least one terminal connector being at least partly disposed in the interior of the cooling jacket.
- the at least one terminal connector is configured for establishing an electrical contact with at least one electrical wire, with the at least one wire being fixed and electrically connected to the at least one terminal connector, whereby the at least one electrical wire may be introduced into the cooling jacket via one of the fluid ports. Hence, the electrical contact between the contact element and the at least one electrical wire is established in the interior of the cooling jacket.
- Both the contact element and the at least one electrical wire may carry electrical current.
- the at least one electrical wire may be part of a power cable adapted for supplying large currents. The larger the currents, the more heat is deposited in the contact element and the at least one wire.
- the cooling jacket is configured for removing the heat that has been deposited.
- the cooling jacket comprises a first fluid port and a second fluid port configured for being connected with a first tube and a second tube. A flow of coolant can be supplied via one of the tubes, is conveyed through the cooling jacket and is withdrawn via the other tube, and heat deposited in the contact element or in the at least one electrical wire can be effectively removed.
- the cooling jacket can for example be part of a cooling circuit and is capable of providing an enclosed volume of coolant configured for cooling the contact element.
- the contact element is enclosed by the connecting sleeve in a fluid-tight manner, whereby at least a part of the at least one terminal connector is located inside the cooling jacket.
- the cooling jacket is manufactured in one piece and is made of a polymeric material. As the cooling jacket is made in one piece, the cooling jacket is capable of hermetically sealing and encapsulating the enclosed volume of coolant, thereby reducing safety hazards. The cooling jacket provides a robust enclosure that is not prone to damages.
- the plug-in connector comprises a contact element with a connector element and at least one terminal connector and a cooling jacket with a connecting sleeve for accommodating the contact element, a first fluid port adapted for fluidically connecting the cooling jacket with a first tube and a second fluid port adapted for fluidically connecting the cooling jacket with a second tube.
- the cooling jacket is manufactured in one piece and the cooling jacket is made of a polymeric material.
- An outer surface of the contact element is encompassed by the connecting sleeve in a fluid-tight manner, wherein the connector element is at least partly exposed to the outside of the cooling jacket and wherein the at least one terminal connector is at least partly disposed in the interior of the cooling jacket.
- the at least one terminal connector is configured for being electrically connected with at least one electrical wire that is introducible into the cooling jacket via at least one of the fluid ports.
- the method comprises supplying a flow of coolant to the second fluid port, wherein the coolant passes the cooling jacket's interior, with the coolant impinging on the at least one terminal connector of the contact element or on an insulating sheath enclosing the at least one terminal connector, and withdrawing a flow of coolant at the first fluid port. Accordingly, the fluid impinging on the at least one terminal connector is capable of discharging heat with high efficiency and at a considerable rate.
- a plug-in connector comprises a contact element with a connector element and at least one terminal connector and a cooling jacket with a first fluid port adapted for fluidically connecting the cooling jacket with a first tube and a second fluid port adapted for fluidically connecting the cooling jacket with a second tube.
- the cooling jacket further comprises a connecting sleeve for accommodating the contact element. An outer surface of the contact element is encompassed by the connecting sleeve in a fluid-tight manner, wherein the connector element is at least partly exposed to the outside of the cooling jacket and wherein the at least one terminal connector is at least partly disposed in the interior of the cooling jacket.
- the at least one terminal connector is configured for being electrically connected with at least one electrical wire that is introducible into the cooling jacket via at least one of the fluid ports.
- the plug-in connector further comprises an insulating sheath configured for electrically insulating the contact element relative to a coolant in the interior of the cooling jacket.
- the insulating sheath is configured for electrically insulating the parts of the contact elements that are exposed to the coolant, in particular the at least one terminal connector, relative to the coolant.
- the coolant is electrically insulated relative to the current carrying parts of the plug-in connector, thereby reducing safety hazards.
- the choice of possible coolants is widened, because also conductive coolants like for example water can be employed.
- safety requirements on the housing can be lowered.
- the plug-in connector comprises a contact element with a connector element and at least one terminal connector and a cooling jacket with a connecting sleeve for accommodating the contact element, a first fluid port adapted for fluidically connecting the cooling jacket with a first tube and a second fluid port adapted for fluidically connecting the cooling jacket with a second tube.
- An outer surface of the contact element is encompassed by the connecting sleeve in a fluid-tight manner, wherein the connector element is at least partly exposed to the outside of the cooling jacket and wherein the at least one terminal connector is at least partly disposed in the interior of the cooling jacket.
- the at least one terminal connector is configured for being electrically connected with at least one electrical wire that is introducible into the cooling jacket via at least one of the fluid ports.
- the plug-in connector further comprises an insulating sheath configured for electrically insulating the contact element relative to a coolant in the interior of the cooling jacket.
- the method comprises supplying a flow of coolant to the second fluid port, wherein the coolant passes the cooling jacket's interior, with the coolant impinging on the insulating sheath, and withdrawing a flow of coolant at the first fluid port.
- the cooling jacket is made of an elastomer.
- An elastomer is an elastically deformable polymeric material. Elastomers comprise for example natural rubber and synthetic rubber. Polymer chains are held together in elastomers by weak intermolecular forces. These weak binding forces permit the polymers to be stretched.
- the application temperature of an elastomer is above the glass transition temperature.
- the cooling jacket is made of an elastomer, the fluid ports and the connecting sleeve can be pressed against the respective tube or against the contact element and thus establish a fluid-tight sealing. As a consequence, no extra sealing gaskets or O-rings are required.
- a cooling jacket made of an elastomer provides a robust enclosure that is not prone to damages.
- the cooling jacket is made of an elastomer with a glass transition temperature below 0° C.
- the cooling jacket is made of an elastomer with a glass transition temperature below -10° C.
- the cooling jacket is made of an elastomer with a glass transition temperature below -20° C.
- the cooling jacket is made of an elastomer with a glass transition temperature below -30° C.
- the cooling jacket is made of an elastomer with a glass transition temperature below -50° C.
- the elastomer is one of a fluoroelastomer, nitrile rubber, polychloroprene, silicone rubber.
- Fluoroelastomers like for example FKM, nitrile rubbers like for example nitrile butadiene rubber (NBR), polychloroprene, neoprene and silicone rubber are suitable materials for manufacturing the cooling jacket.
- the cooling jacket is made of a material having a Shore hardness above 30 Shore-A.
- the cooling jacket is made of a material having a Shore hardness above 40 Shore-A.
- the cooling jacket is made of a material having a Shore hardness above 50 Shore-A.
- the cooling jacket is made of a material having a Shore hardness below 98 Shore-A.
- the cooling jacket is made of a material having a Shore hardness below 95 Shore-A.
- the cooling jacket is made of a material having a Shore hardness below 90 Shore-A.
- the cooling jacket is made of a material having a Shore hardness below 80 Shore-A.
- the cooling jacket is made of a material having a Shore hardness below 70 Shore-A. These ranges of the Shore-A hardness are characteristic for a rubber-like behavior. Accordingly, the cooling jacket itself can act as a sealing element when being pressed against another element.
- the connecting sleeve may be circumferentially pressed against the contact element to establish a fluid-tight connection.
- the fluid ports may be circumferentially pressed against a tube to establish a fluid-tight coupling.
- Another advantage is that a material of the cooling jacket with a hardness in the range indicated above does not tend to break, but can flexibly adapt to forces and pressures. Thus, the cooling jacket is not prone to be damaged. Furthermore, the cooling jacket can adapt to a rigid housing of the plug-in connector that encompasses the cooling jacket.
- the cooling jacket possesses elastic properties.
- elastic behavior shall mean that the material of the cooling jacket is deformed if forces or pressures act on it, but as soon as the force or the pressure is not applied to the cooling jacket anymore, the cooling jacket will reassume its initial shape.
- the cooling jacket is made of a rubber-elastic material.
- the plug-in connector further comprises a housing, said housing encompassing the cooling jacket, wherein a support provided by the housing is adapted for limiting a deformation or expansion of the cooling jacket.
- a support provided by the housing is adapted for limiting a deformation or expansion of the cooling jacket.
- the cooling jacket will be pressurised and may accordingly expand or bulge out.
- the connecting sleeve is disposed at a first end in an axial direction of the plug-in connector, wherein the first fluid port is disposed at a second end opposite to the first end in the axial direction and wherein the second fluid port is disposed at a lateral position of the cooling jacket.
- fluid and in particular a coolant, may be supplied to the second fluid port, whereas at the first fluid port, fluid is withdrawn after having passed through the cooling jacket's interior.
- the contact element comprises the connector element, a central section and the at least one terminal connector, with the central section being circumferentially encompassed by the connecting sleeve.
- the connector element is at least partly exposed to the outside of the cooling jacket.
- the connector element may for example be a connector plug or a connector socket.
- the connector element may for example be plugged into a mating connector. By plugging the connector element into the corresponding mating connector, a plug-in connection between the plug-in connector and the mating connector is established.
- the at least one terminal connector is at least partly located in the interior of the cooling jacket.
- the terminal connector(s) can be exposed to a flow of coolant in the interior of the cooling jacket and heat deposited in the contact element can be removed.
- the at least one terminal connector may be electrically connected with one or more electrical wires that are led into the cooling jacket via one of the fluid ports.
- the electrical wires can be cooled by a flow of coolant in the cooling jacket as well.
- at least one of the terminal connectors is implemented as a contact sleeve.
- a contact sleeve allows for accommodating and connecting an electrical wire.
- techniques like for example crimping, welding, screwing, clamping and others may be used.
- the contact sleeve may for example be implemented as a crimping sleeve or as an axial screw terminal.
- the contact element comprises several terminal connectors, each of the several connectors being adapted for being electrically connected with an electrical wire.
- the contact element may either comprise a single terminal connector, but it may as well comprise several terminal connectors.
- the interior of the cooling jacket is adapted for being pressurised by a fluid supplied via at least one of the fluid ports.
- the cooling jacket may for example be hermetically sealed.
- the cooling jacket can be pressurised by the flow of coolant provided via at least one of the fluid ports.
- a flow of coolant can be conveyed through the cooling jacket.
- the terminal connector does not comprise any additional conduits or channels for increasing the interaction between the coolant and the terminal connector.
- the terminal connector does not comprise a dedicated channel for conveying coolant through the terminal connector. It has been found that for an effective cooling operation, the flow resistance within the cooling jacket has to be kept low. For removing the heat deposited in the terminal connector, it is not necessary to provide for additional conduits and channels traversing the terminal connectors. A sheath flow encompassing the terminal connectors is sufficient.
- a flow of coolant is supplied to the cooling jacket, and via the first fluid port, a flow of coolant is withdrawn from the cooling jacket.
- the flow of coolant is supplied via the second fluid port, which is preferably located at a lateral position of the cooling jacket.
- the flow of fluid is directly supplied to the at least one connector terminal, which provides for an effective cooling.
- the coolant is a gas or a liquid.
- the cooling jacket is fluid-tightly sealed, it is also possible to pass a gas through the cooling jacket.
- the second fluid port is disposed at a lateral position of the cooling jacket, wherein the at least one terminal connector is arranged such that a flow of coolant supplied via the second fluid port impinges on the at least one terminal connector or on an insulating sheath enclosing the at least one terminal connector.
- the second fluid port is located at a lateral position close to the connector element.
- the plug-in connector further comprises the at least one electrical wire, with each of the electrical wires being electrically connected with a corresponding terminal connector, wherein the at least one electrical wire and at least the part of the contact element that is exposed to a coolant supplied via at least one of the fluid ports are insulated relative to the coolant.
- the coolant does not get in direct contact with the current carrying elements. Accordingly, an electrically conductive coolant like for example water may be used.
- the plug-in connector further comprises an insulating sheath configured for electrically insulating the contact element relative to a coolant in the interior of the cooling jacket.
- the current carrying parts can be electrically insulated relative to the coolant, thereby reducing safety hazards.
- at least the part of the contact element that is exposed to a coolant supplied via at least one of the fluid ports is insulated with an insulating sheath.
- the insulating sheath is integrally formed with the cooling jacket. Forming the cooling jacket and the insulating sheath in one piece provides for a reliable insulation.
- the insulating sheath may be implemented as a separate part.
- the insulating sheath overlaps with the cable insulation.
- the coolant is an electrically conductive coolant.
- the plug-in connector further comprises the first tube, said first tube being fluid-tightly connected with the first fluid port.
- the first tube is used for withdrawing coolant from the cooling jacket.
- the plug-in connector further comprises the second tube, said second tube being fluid-tightly connected with the second fluid port.
- the second tube is used for supplying coolant to the cooling jacket.
- the cooling jacket is configured for receiving a flow of coolant via the second tube, for conveying the coolant through the cooling jacket's interior and for supplying the flow of coolant to the first tube.
- the plug-in connector further comprises the at least one electrical wire, with each of the electrical wires being electrically connected with a corresponding terminal connector.
- the at least one electrical wire is led into the cooling jacket via the first fluid port.
- the at least one electrical wire is encompassed by the first tube.
- the cable comprising one or more electrical wires is arranged within one of the first or the second tube and is led into the cooling jacket via one of the fluid ports.
- the at least one electrical wire may for example be enclosed by a flow of coolant, and accordingly, the cable is effectively cooled.
- the interspace between the electrical cable and the first tube may for example provide a fluid conduit for the flow of coolant.
- a dedicated channel for the coolant may for example be provided in the first tube.
- the at least one electrical wire is encompassed by the first tube, with an interspace for conducting a flow of coolant being formed between the at least one electrical wire and the first tube.
- a flow of coolant flowing in the interspace provides for a cooling of the at least one electrical wire enclosed by the first tube.
- the flow of coolant may for example encompass the at least one electrical wire at all sides, which allows for an effective transfer of heat.
- the first fluid port is implemented as a connecting sleeve. Further preferably, the first fluid port is implemented as a connecting sleeve configured for circumferentially encompassing the first tube.
- the second fluid port is implemented as a connecting sleeve. Further preferably, the second fluid port is implemented as a connecting sleeve configured for circumferentially encompassing the second tube.
- the first fluid port and the second fluid port are implemented as separate fluid ports.
- the first fluid port and the second fluid port are implemented as separate connecting sleeves. Further preferably, the first fluid port and the second fluid port are spaced apart from one another.
- the plug-in connector further comprises a fastening ring adapted for fluid-tightly pressing the first fluid port against the first tube disposed in the first connecting sleeve.
- the plug-in connector further comprises a fastening ring adapted for fluid-tightly pressing the second fluid port against the second tube disposed in the second connecting sleeve.
- the plug-in connector further comprises a fastening ring adapted for fluid-tightly pressing the connecting sleeve against the central section of the contact element.
- a joining technique like crimping or flanging may for example be used for fluid-tightly pressing the connecting sleeve against the central section of the contact element.
- the plug-in connector further comprises a second contact element
- the cooling jacket further comprising a second connecting sleeve for accommodating the second contact element, with an outer surface of the second contact element being encompassed by the second connecting sleeve in a fluid-tight manner.
- the cooling jacket can be used for cooling two or more contact elements.
- the cooling jacket may comprise two or more connecting sleeves for accommodating the contact elements.
- the second contact element comprises a second connector element and at least one second terminal connector, wherein the second connector element is at least partly exposed to the outside of the cooling jacket and wherein the at least one second terminal connector is at least partly disposed in the interior of the cooling jacket.
- the plug-in connector is a charging connector adapted for performing a charging operation.
- a charging operation and in particular in a fast charging operation, large currents are supplied to an electric vehicle. The larger the current, the more heat will be dissipated.
- the cooling jacket allows to establish a thermal contact between the terminal connectors and the coolant and accordingly, the large amount of heat dissipated during the charging operation can be discharged.
- the plug-in connector is configured for carrying an electrical current above 80 Ampere.
- the charging connector is adapted for being connected with a charge port of an electric vehicle.
- the mating direction when plugging the charging connector into a charge port is an axial direction of the charging connector.
- Plug-in connector with cooling Jacket manufactured in one piece
- the following embodiments relate to a plug-in connector comprising a cooling jacket manufactured in one piece, the cooling jacket being made of a polymeric material.
- At least part of the at least one terminal connector is exposed to a coolant supplied via at least one of the fluid ports.
- the coolant is in direct contact with the at least one terminal connector of the contact element.
- the transfer of heat from the at least one terminal connector to the coolant is intensified.
- the coolant is a non-conductive coolant.
- cooling is required for plug-in connectors that carry large currents.
- a non-conductive coolant like for example oil is used, in order to avoid safety hazards.
- At least one of the terminal connectors is encompassed by a sheath flow of coolant.
- the sheath flow may for example enclose the terminal connector at all sides and may flow along the entire length of the terminal connector, thereby removing heat deposited in the contact element.
- a sheath flow of coolant provides for an effective removal of heat without unduly increasing flow resistance.
- the following embodiments relate to a plug-in connector comprising an insulating sheath configured for electrically insulating the contact element relative to a coolant in the interior of the cooling jacket.
- the insulating sheath is integrally formed with the cooling jacket. Forming the cooling jacket and the insulating sheath in one piece provides a most reliable electrical insulation. Alternatively, the insulating sheath may be implemented as a separate part.
- the cooling jacket is made of a rigid material.
- the cooling jacket stabilises the plug-in connector and provides a rigid support. No additional support is required.
- the cooling jacket is made of a polymeric material.
- the cooling jacket is made of hard plastic or of metal.
- the cooling jacket is made of two or more parts. Providing a cooling jacket made of two or more parts may simplify the assembly, because the parts may be fitted from different directions.
- Figure 1 shows a longitudinal section of a plug-in connector 1.
- the plug-in connector 1 shown in figure 1 is particularly suited for carrying large electrical currents.
- the plug-in connector 1 may for example be a charging connector for a fast-charging vehicle charger, but it may as well be used for other applications where large electrical currents of for example 80 Ampere or more occur.
- the plug-in connector 1 comprises a cooling circuit configured for conveying a flow of coolant through the plug-in connector 1.
- the plug-in connector 1 comprises a contact element 2 made of conductive material, preferably metal.
- the contact element 2 comprises a connector element 4, a central section 5 and a terminal connector 6.
- the connector element 4 comprises a protective pin 7 and split fingers 8, with the connector element 4 being configured for establishing a plug-in connection with a mating male connector, for example with a charge port of an electric vehicle.
- the mating direction for establishing the plug-in connection between the connector element 4 and the mating male connector corresponds to the axial direction 3 indicated in figure 1 .
- the plug-in connector 1 shown in figure 1 comprises a cooling jacket 9 made of a polymeric material, preferably of an elastomer.
- the cooling jacket 9 comprises a connecting sleeve 10 at a first end.
- the connecting sleeve 10 is configured for accommodating the central section 5 of the contact element 2.
- the contact element 2 is partly exposed to the outside of the cooling jacket 9 and partly disposed inside of the cooling jacket 9.
- the connector element 4 is located outside of the cooling jacket 9, whereas the terminal connector 6 is located in the interior of the cooling jacket 9.
- the central section 5 is integrally formed with the connector element 4 and with the terminal connector 6.
- the contact element 2 is manufactured as a single piece, preferably as a rotationally symmetric piece.
- the connector element 4, the central section 5 and the terminal connector 6 may be manufactured as separate parts, which are then mechanically and electrically connected.
- the central section 5 preferably has an essentially cylindrical shape, with the outer surface being circumferentially enclosed by the connecting sleeve 10. Due to the elastic properties of the cooling jacket 9, a fluid-tight sealing between the connecting sleeve 10 and the central section 5 can be obtained by pressing the connecting sleeve 10 against the central section 5.
- a fastening ring 11 that encloses both the central section 5 and the connecting sleeve 10 can be used for circumferentially pressing the connecting sleeve 10 against the central section 5, thereby establishing a fluid-tight connection.
- joining techniques like for example crimping or flanging can be employed for establishing a fluid-tight connection between the central section 5 and the connecting sleeve 10.
- joining techniques like for example crimping or flanging can be employed for establishing a fluid-tight connection between the central section 5 and the connecting sleeve 10.
- no additional sealing gaskets or O-ring seals are required.
- the terminal connector 6 is located in the interior of the cooling jacket 9 and is configured for establishing an electrical connection with an electrical wire 12.
- the terminal connector 6 may for example be implemented as a contact sleeve configured for accommodating the electrical wire 12.
- the electrical wire 12 is inserted into the contact sleeve and fastened in the contact sleeve.
- the electrical wire may be fixed in the contact sleeve by means of screws, clamps, crimping, welding, in particular ultrasonic welding or resistance welding, etc.
- the electrical wire 12 may for example carry a current of 80 Ampere or more, and accordingly, it is important to establish a reliable electrical connection of low contact resistance between the terminal connector 6 and the electrical wire 12.
- the cooling jacket 9 is adapted for realising a cooling circuit for cooling both the terminal connector 6 and the electrical wire 12.
- the cooling jacket 9 further comprises two fluid ports 13 and 14.
- the first fluid port 13 is located at a second end of the cooling jacket 9, opposite to the connecting sleeve 10.
- the second fluid port 14 is located at a lateral position of the cooling jacket 9, with the second fluid port 14 being connected via a tubing 15 with a lateral inlet 16 that branches off laterally from the axial flow path of the cooling jacket 9.
- the cooling jacket 9 is shown separately.
- the cooling jacket 9 is manufactured in one piece and comprises three openings.
- the connecting sleeve 10 is arranged.
- the first fluid port 13 is disposed, and at a lateral position thereto, the second fluid port 14 is arranged, the second fluid port 14 being fluidically connected via the tubing 15 with the lateral inlet 16.
- the electrical wire 12 is inserted into the terminal connector 6. Furthermore, the first fluid port 13 is configured for establishing a fluidic connection with a first tube 17. For establishing the fluid-tight connection, the first tube 17 is inserted into the first fluid port 13 in a way that the first fluid port 13 encompasses the end of the first tube 17. Then, the first fluid port 13, which may be implemented as a connecting sleeve, is circumferentially pressed against the end of the first tube 17. For example, the first fluid port 13 may be pressed against the first tube 17 by means of a fastening ring 18 to provide for a fluid-tight sealing.
- the first tube 17 encloses the electrical wire 12 in a way that an interspace 19 is formed between the first tube 17 and the electrical wire 12. Via the interspace 19, a flow of coolant can be withdrawn from the interior of the cooling jacket 9. Thus, the first tube 17 encompasses the electrical wire 12, with coolant being conducted in the interspace 19 between the electrical wire 12 and the first tube 17.
- a fluidic connection with the second tube 20 can be set up.
- the end of the second tube 20 is inserted into the second fluid port 14, which may be implemented as a connecting sleeve.
- the fluid port 14 is circumferentially pressed against the end of the second tube 20.
- a fastening ring 21 is used for fixing the second tube 20.
- joining techniques like crimping and flanging may be used for establishing a fluid-tight connection. In case a cooling jacket 9 with sufficient elasticity is used, no extra sealing gasket or O-ring is required at the first fluid port 13 and the second fluid port 14.
- a flow of coolant is provided to the cooling jacket 9.
- the incoming flow of coolant is conveyed by a tubing 15 to the lateral inlet 16 and impinges on the terminal connector 6.
- the terminal connector 6 is in direct contact with the coolant, thus providing for an effective transfer of heat from the contact element 2 to the coolant.
- This direct cooling effectively removes heat deposited in the terminal connector 6 and in the contact element 2.
- the flow of coolant is redirected and, as indicated by the arrows 22, along the entire length of the terminal connector 6 a sheath flow is formed.
- the flow of coolant is injected into the interspace 19 between the electrical wire 12 and the first tube 17 and flows along the electrical wire 12.
- the flow of coolant encompasses the electrical wire 12 and provides for an effective cooling of the electrical wire 12.
- the coolant is in immediate contact with the terminal connector 6, which is made of conductive material. Accordingly, a non-conductive coolant like for example oil or gas should be used.
- the plug-in connector 1 shown in figure 1 further comprises a rigid housing 23 that encompasses at least a part of the cooling jacket 9.
- the interior of the cooling jacket 9 is fluid-tightly sealed and can therefore be pressurised by a coolant supplied via at least one of the fluid ports 13, 14. As a result thereof, the cooling jacket 9 may bulge out.
- the cooling jacket 9 is preferably encompassed by the rigid housing 23.
- the cooling jacket 9 is slid on the first tube 17 in the direction to the right of figure 1 .
- the cooling jacket 9 is moved so far to the right that the electrical wire 12 can be electrically connected with the terminal connector 6 of the contact element 2.
- the electrical connection may for example be established by one of screwing, clamping, welding, crimping, etc.
- the cooling jacket 9 is moved in the direction to the left of figure 1 , wherein the central section 5 of the contact element 2 is inserted into the connecting sleeve 10 of the cooling jacket 9.
- the first fluid port 13 is in its final position relative to the first tube 17.
- the connecting sleeve 10 is fixed relative to the central section 5 by the fastening ring 11 and the first fluid port 13 is fixed relative to the first tube 17 by the fastening ring 18. Then, the second tube 20 is slid into the second fluid port 14 and the second fluid port 14 is fixed relative to the second tube 20 by the fastening ring 21.
- FIG 3 a further example of a plug-in connector 24 is depicted.
- the plug-in connector 24 comprises a cooling circuit for removing heat that has been dissipated in the conductor.
- the electrical parts that may carry large electrical currents are electrically insulated relative to the coolant.
- the plug-in connector 24 comprises a contact element 25 made of an electrically conductive material, preferably of metal.
- the contact element 25 comprises a connector element 26, a central section 27 and a terminal connector 28.
- the connector element 26 comprises a socket with a lamellae basket 29.
- the connector element 26 is configured for establishing an electric contact with a mating male connector when the plug-in connector 24 is connected with the mating male connector, with the mating direction being the axial direction 30 indicated in figure 3 .
- the plug-in connector 24 comprises a cooling jacket 31 made of a polymeric material, preferably of an elastomer.
- the cooling jacket 31 comprises a connecting sleeve 32, a first fluid port 33 and a second fluid port 34.
- the connecting sleeve 32 is located at a first end, whereas the first fluid port 33 is disposed at a second end opposite to the first end.
- the second fluid port 34 is located at a lateral position of the cooling jacket 31.
- the connecting sleeve 32 is configured for accommodating the central section 27 of the contact element 25.
- the connecting sleeve 32 is circumferentially pressed against the central section 27.
- a fastening ring 35 may be employed for establishing a fluid-tight seal, but other joining techniques like crimping or flanging can be used as well.
- the connecting sleeve 32 is made of an elastomer, no extra sealing gaskets or O-rings are required.
- the terminal connector 28 which may for example be implemented as a contact sleeve, is configured for establishing an electrical connection with the electrical wire 36.
- the electrical wire 36 is inserted via the first fluid port 33 into the interior of the cooling jacket 31 and fastened in the terminal connector 28.
- both the terminal connector 28 and the electrical wire 36 are electrically insulated relative to the coolant flowing in the cooling jacket 31.
- the electrical wire 36 is equipped with a cable insulation 37.
- an insulating sheath 38 is provided, said insulating sheath 38 being integrally formed with the cooling jacket 31.
- the insulating sheath may be realised as a separate part.
- the insulating sheath 38 covers and insulates the terminal connector 28 and overlaps with the cable insulation 37 of the electrical wire 36.
- a fastening ring 39 may be used for pressing the insulating sheath 38 against the cable insulation 37 of the electrical wire 36.
- joining techniques like crimping or flanging can be used for fixing the electrical insulation. As a result, all current carrying parts are electrically insulated relative to the coolant flowing in the cooling jacket 31.
- the first fluid port 33 of the cooling jacket 31 is configured for establishing a fluidic connection with a first tube 40.
- the electrical wire 36 is enclosed by the first tube 40 and an interspace 41 is formed between the cable insulation 37 and the first tube 40.
- a spacer ring 42 is inserted between the cable insulation 37 and the first tube 40. Via the spacer ring 42, a flow of coolant can be injected into the interspace 41 and withdrawn from the cooling jacket 31.
- the cooling jacket 31 with the electrical wire 36 is slid onto the first tube 40.
- the first fluid port 33 which may for example be realised as a connecting sleeve, is circumferentially pressed against the first tube 40 and the spacer ring 42.
- a fastening ring 43 may be used for securing a fluid-tight connection or a joining technique like crimping or flanging may be employed.
- the first fluid port 33 is made of an elastomer, no extra sealing gaskets or O-rings are required.
- the second fluid port 34 is adapted for accommodating the second tube 44.
- the second tube 44 is inserted into the second fluid port 34 and the fluid-tight connection is fastened by a fastening ring 45.
- the cooling jacket 31 is adapted for realising a cooling circuit for cooling both the terminal connector 28 and the electrical wire 36.
- a flow of coolant is supplied to the second fluid port 34 via the second tube 44, as indicated by arrow 46.
- the flow of coolant impinges on the insulating sheath 38, thereby effecting a cooling of the terminal connector 28 and the electrical wire 36.
- the flow of coolant is redirected as indicated by arrow 47. Via the passageways of the spacer ring 42, the flow of fluid is injected into the interspace 41, thereby cooling the electrical wire 36.
- the cooling jacket 31 As the cooling jacket 31 is fluid-tightly sealed, it can be pressurised by a coolant supplied via an at least one of the fluid ports 33, 34. In order to restrict any volumetric deformation of the cooling jacket 31, the cooling jacket 31 is preferably encompassed by a rigid housing, which is not shown in figure 3 .
- FIG. 4 shows another embodiment of a plug-in connector 48, with said plug-in connector 48 comprising a cooling circuit for removing heat that has been deposited in the plug-in connector.
- the plug-in connector 48 comprises a contact element 49 with a connector element 50, a central section 51 and a terminal connector 52, wherein the terminal connector 52 is configured for establishing an electric connection with the electrical wire 53.
- the plug-in connector 48 further comprises a cooling jacket 54 that provides fluidic pathways for cooling the terminal connector 52 and the electric wire 53.
- the cooling jacket 54 is made of a rigid material.
- the cooling jacket 54 is made of hard plastic or of metal.
- the cooling jacket 54 comprises a connecting sleeve 56, the connecting sleeve 56 being disposed at a first end of the plug-in connector 48 in the axial direction 55.
- the connecting sleeve 56 is configured for accommodating the contact element 49 and for circumferentially enclosing the central section 51 of the contact element 49 in a fluid-tight manner.
- a first fluid port 57 is arranged at the opposite end of the cooling jacket 54 viewed in the axial direction 55.
- the first fluid port 57 is configured for establishing a fluidic connection with a first tube 58.
- the cooling jacket 54 further comprises a second fluid port 59, the second fluid port 59 being fluidically connected with an inlet 60 disposed at a lateral position of the cooling jacket 54.
- the second fluid port 59 is adapted for establishing a fluidic connection with a second tube 61.
- the electrically conductive parts located inside the cooling jacket 54 are insulated relative to the coolant.
- the electrical wire 53 is provided with a cable insulation 62 and the terminal connector 52 is enclosed by an insulating sheath 63.
- the insulating sheath 63 is circumferentially pressed against the cable insulation 62 by a fastening ring 64. Accordingly, both the electrical wire 53 and the terminal connector 52 are insulated relative to the coolant.
- the first tube 58 encompasses the electrical wire 53, whereby an interspace 66 is formed between the cable insulation 62 and the first tube 58.
- the spacer ring 68 is inserted between the cable insulation 62 and the first tube 58. Via the spacer ring 68, a flow of coolant can be injected into the interspace 66 and withdrawn from the cooling jacket 54.
- the electrical wire 53 is connected with the terminal connector 52 and the insulating sheath 63 is disposed around the terminal connector 52 and overlaps with the cable insulation 62. Then, the cooling jacket 54 and a sealing ring 69 positioned in the recess 67 are slid onto the contact element 49. Finally, a cap 70 is attached to the first fluid port 57.
- the cap 70 may for example be attached to the first fluid port 57 using a flanging tool.
- the second tube 61 is attached to the second fluid port 59 and fixed by a fastening ring 71.
- a flow of coolant is conveyed from the second tube 61 via the second fluid port 59 to the interior of the cooling jacket 54.
- a sheath flow of coolant is established.
- the coolant is then injected into the interspace 66 between the cable insulation 62 and the first tube 58.
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- Engineering & Computer Science (AREA)
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- Mechanical Engineering (AREA)
- Connector Housings Or Holding Contact Members (AREA)
Abstract
Description
- The invention relates to a plug-in connector. The invention further relates to a method for operating a plug-in connector.
- US Patent
US 9 321 362 B2 US 2015/0217654 A1 andUS 2016/0200206 A1 relate to cooling of a charging cable. A charging system for an electric vehicle is disclosed, the charging system including a power supply, a cable having first and second ends, the first end attached to the power supply, with the cable comprising a charging conductor and a cooling conduit, each of which extends from the first end to the second end. The charging system further comprises a connector attached to the second end of the cable, the connector having a form factor corresponding to a charge port of the electric vehicle. The cooling conduit is adapted to convey a fluid that cools the charging conductor. - German
Patent Application DE 10 2015 100 347 A1 describes an electrical connecting element for a charging connector and/or a charge port and to a charging connector and a charging station for supplying electrical energy to a recipient. An electrical connecting element for a charging connector and/or a charge port is described, wherein the electrical connecting element comprises a first connecting zone for a galvanic connection with an electrical power recipient and a second connecting zone for a galvanic connection with an electric power source, with the electrical connecting element comprising a cooling fluid channel that is formed in the electrical connecting element. Furthermore, a charging connector for coupling with a corresponding coupling apparatus and for transmission of electrical energy is disclosed, wherein the charging connector comprises an electrical connecting element, with the cooling fluid channel of the electrical connecting element being fluidically connected with a source of cooling fluid. Furthermore, a charging station for supplying electrical energy to a recipient is disclosed, wherein the charging station comprises a charging connector and a source of cooling fluid that is fluidically connectable with a cooling fluid channel of the electrical connecting element. - The object of the invention is to provide a plug-in connector with a cooling facility that allows to effectively discharge heat.
- According to the invention, a plug-in connector is provided. The plug-in connector comprises a contact element with a connector element and at least one terminal connector and a cooling jacket with a first fluid port adapted for fluidically connecting the cooling jacket with a first tube and a second fluid port adapted for fluidically connecting the cooling jacket with a second tube. The cooling jacket further comprises a connecting sleeve for accommodating the contact element, wherein the cooling jacket is manufactured in one piece and wherein the cooling jacket is made of a polymeric material. An outer surface of the contact element is encompassed by the connecting sleeve in a fluid-tight manner, wherein the connector element is at least partly exposed to the outside of the cooling jacket and wherein the at least one terminal connector is at least partly disposed in the interior of the cooling jacket. The at least one terminal connector is configured for being electrically connected with at least one electrical wire that is introducible into the cooling jacket via at least one of the fluid ports.
- The contact element is made of an electrically conductive material, preferably of metal. The contact element comprises a connector element that is at least partly exposed to the outside of the cooling jacket. The connector element may for example be configured for electrically contacting a contact element of a mating connector or for being plugged into a mating connector. For example, the connector element may be implemented as a connector plug or a connector socket. The contact element further comprises at least one terminal connector, with the at least one terminal connector being at least partly disposed in the interior of the cooling jacket. The at least one terminal connector is configured for establishing an electrical contact with at least one electrical wire, with the at least one wire being fixed and electrically connected to the at least one terminal connector, whereby the at least one electrical wire may be introduced into the cooling jacket via one of the fluid ports. Hence, the electrical contact between the contact element and the at least one electrical wire is established in the interior of the cooling jacket.
- Both the contact element and the at least one electrical wire may carry electrical current. For example, in case of a charging connector, the at least one electrical wire may be part of a power cable adapted for supplying large currents. The larger the currents, the more heat is deposited in the contact element and the at least one wire. The cooling jacket is configured for removing the heat that has been deposited. The cooling jacket comprises a first fluid port and a second fluid port configured for being connected with a first tube and a second tube. A flow of coolant can be supplied via one of the tubes, is conveyed through the cooling jacket and is withdrawn via the other tube, and heat deposited in the contact element or in the at least one electrical wire can be effectively removed. The cooling jacket can for example be part of a cooling circuit and is capable of providing an enclosed volume of coolant configured for cooling the contact element. The contact element is enclosed by the connecting sleeve in a fluid-tight manner, whereby at least a part of the at least one terminal connector is located inside the cooling jacket. Hence, the interaction of the flow of coolant with the part of the contact element that is located inside of the cooling jacket provides for an effective transfer of heat from the contact element to the flow of coolant.
- The cooling jacket is manufactured in one piece and is made of a polymeric material. As the cooling jacket is made in one piece, the cooling jacket is capable of hermetically sealing and encapsulating the enclosed volume of coolant, thereby reducing safety hazards. The cooling jacket provides a robust enclosure that is not prone to damages.
- Further according to the invention, a method for operating a plug-in connector is provided. The plug-in connector comprises a contact element with a connector element and at least one terminal connector and a cooling jacket with a connecting sleeve for accommodating the contact element, a first fluid port adapted for fluidically connecting the cooling jacket with a first tube and a second fluid port adapted for fluidically connecting the cooling jacket with a second tube. The cooling jacket is manufactured in one piece and the cooling jacket is made of a polymeric material. An outer surface of the contact element is encompassed by the connecting sleeve in a fluid-tight manner, wherein the connector element is at least partly exposed to the outside of the cooling jacket and wherein the at least one terminal connector is at least partly disposed in the interior of the cooling jacket. The at least one terminal connector is configured for being electrically connected with at least one electrical wire that is introducible into the cooling jacket via at least one of the fluid ports. The method comprises supplying a flow of coolant to the second fluid port, wherein the coolant passes the cooling jacket's interior, with the coolant impinging on the at least one terminal connector of the contact element or on an insulating sheath enclosing the at least one terminal connector, and withdrawing a flow of coolant at the first fluid port. Accordingly, the fluid impinging on the at least one terminal connector is capable of discharging heat with high efficiency and at a considerable rate.
- Further according to the invention, a plug-in connector is provided. The plug-in connector comprises a contact element with a connector element and at least one terminal connector and a cooling jacket with a first fluid port adapted for fluidically connecting the cooling jacket with a first tube and a second fluid port adapted for fluidically connecting the cooling jacket with a second tube. The cooling jacket further comprises a connecting sleeve for accommodating the contact element. An outer surface of the contact element is encompassed by the connecting sleeve in a fluid-tight manner, wherein the connector element is at least partly exposed to the outside of the cooling jacket and wherein the at least one terminal connector is at least partly disposed in the interior of the cooling jacket. The at least one terminal connector is configured for being electrically connected with at least one electrical wire that is introducible into the cooling jacket via at least one of the fluid ports. The plug-in connector further comprises an insulating sheath configured for electrically insulating the contact element relative to a coolant in the interior of the cooling jacket.
- The insulating sheath is configured for electrically insulating the parts of the contact elements that are exposed to the coolant, in particular the at least one terminal connector, relative to the coolant. Thus, it can be accomplished that the coolant is electrically insulated relative to the current carrying parts of the plug-in connector, thereby reducing safety hazards. The choice of possible coolants is widened, because also conductive coolants like for example water can be employed. Furthermore, by providing an additional electrical insulation between the contact element and the coolant, safety requirements on the housing can be lowered.
- Further according to the invention, a method for operating a plug-in connector is provided. The plug-in connector comprises a contact element with a connector element and at least one terminal connector and a cooling jacket with a connecting sleeve for accommodating the contact element, a first fluid port adapted for fluidically connecting the cooling jacket with a first tube and a second fluid port adapted for fluidically connecting the cooling jacket with a second tube. An outer surface of the contact element is encompassed by the connecting sleeve in a fluid-tight manner, wherein the connector element is at least partly exposed to the outside of the cooling jacket and wherein the at least one terminal connector is at least partly disposed in the interior of the cooling jacket. The at least one terminal connector is configured for being electrically connected with at least one electrical wire that is introducible into the cooling jacket via at least one of the fluid ports. The plug-in connector further comprises an insulating sheath configured for electrically insulating the contact element relative to a coolant in the interior of the cooling jacket. The method comprises supplying a flow of coolant to the second fluid port, wherein the coolant passes the cooling jacket's interior, with the coolant impinging on the insulating sheath, and withdrawing a flow of coolant at the first fluid port.
- Preferred features of the invention which may be applied alone or in combination are discussed below and in the dependent claims.
- Preferably, the cooling jacket is made of an elastomer. An elastomer is an elastically deformable polymeric material. Elastomers comprise for example natural rubber and synthetic rubber. Polymer chains are held together in elastomers by weak intermolecular forces. These weak binding forces permit the polymers to be stretched. The application temperature of an elastomer is above the glass transition temperature. In case the cooling jacket is made of an elastomer, the fluid ports and the connecting sleeve can be pressed against the respective tube or against the contact element and thus establish a fluid-tight sealing. As a consequence, no extra sealing gaskets or O-rings are required. Furthermore, a cooling jacket made of an elastomer provides a robust enclosure that is not prone to damages.
- Preferably, the cooling jacket is made of an elastomer with a glass transition temperature below 0° C. Preferably, the cooling jacket is made of an elastomer with a glass transition temperature below -10° C. Preferably, the cooling jacket is made of an elastomer with a glass transition temperature below -20° C. Preferably, the cooling jacket is made of an elastomer with a glass transition temperature below -30° C. Preferably, the cooling jacket is made of an elastomer with a glass transition temperature below -50° C.
- Preferably, the elastomer is one of a fluoroelastomer, nitrile rubber, polychloroprene, silicone rubber. Fluoroelastomers like for example FKM, nitrile rubbers like for example nitrile butadiene rubber (NBR), polychloroprene, neoprene and silicone rubber are suitable materials for manufacturing the cooling jacket.
- Preferably, the cooling jacket is made of a material having a Shore hardness above 30 Shore-A. Preferably, the cooling jacket is made of a material having a Shore hardness above 40 Shore-A. Preferably, the cooling jacket is made of a material having a Shore hardness above 50 Shore-A. Preferably, the cooling jacket is made of a material having a Shore hardness below 98 Shore-A. Preferably, the cooling jacket is made of a material having a Shore hardness below 95 Shore-A. Preferably, the cooling jacket is made of a material having a Shore hardness below 90 Shore-A. Preferably, the cooling jacket is made of a material having a Shore hardness below 80 Shore-A. Preferably, the cooling jacket is made of a material having a Shore hardness below 70 Shore-A. These ranges of the Shore-A hardness are characteristic for a rubber-like behavior. Accordingly, the cooling jacket itself can act as a sealing element when being pressed against another element. For example, the connecting sleeve may be circumferentially pressed against the contact element to establish a fluid-tight connection. Similarly, the fluid ports may be circumferentially pressed against a tube to establish a fluid-tight coupling. By providing a cooling jacket with rubber-like elastic properties, a fluid-tight connection can be accomplished by pressing the cooling jacket against its counterpart. In this respect, no additional sealing gaskets or O-rings are required. Another advantage is that a material of the cooling jacket with a hardness in the range indicated above does not tend to break, but can flexibly adapt to forces and pressures. Thus, the cooling jacket is not prone to be damaged. Furthermore, the cooling jacket can adapt to a rigid housing of the plug-in connector that encompasses the cooling jacket.
- Preferably, the cooling jacket possesses elastic properties. In this regard, elastic behavior shall mean that the material of the cooling jacket is deformed if forces or pressures act on it, but as soon as the force or the pressure is not applied to the cooling jacket anymore, the cooling jacket will reassume its initial shape. Preferably, the cooling jacket is made of a rubber-elastic material.
- Preferably, the plug-in connector further comprises a housing, said housing encompassing the cooling jacket, wherein a support provided by the housing is adapted for limiting a deformation or expansion of the cooling jacket. In case a fluid at a certain pressure is supplied to the cooling jacket via one of the fluid ports, the cooling jacket will be pressurised and may accordingly expand or bulge out. In order to restrict these deformations and prevent any volumetric changes, it may be advantageous to encompass the cooling jacket with a rigid housing that provides additional support and stability.
- Preferably, the connecting sleeve is disposed at a first end in an axial direction of the plug-in connector, wherein the first fluid port is disposed at a second end opposite to the first end in the axial direction and wherein the second fluid port is disposed at a lateral position of the cooling jacket. Further preferably, fluid, and in particular a coolant, may be supplied to the second fluid port, whereas at the first fluid port, fluid is withdrawn after having passed through the cooling jacket's interior. By providing a flow of coolant at a lateral position of the plug-in connector, an effective cooling of the contact element can be accomplished, because the coolant is directly supplied to the rear part of the contact element. Heat generated at the contact element can be effectively removed.
- Preferably, the contact element comprises the connector element, a central section and the at least one terminal connector, with the central section being circumferentially encompassed by the connecting sleeve. The connector element is at least partly exposed to the outside of the cooling jacket. The connector element may for example be a connector plug or a connector socket. The connector element may for example be plugged into a mating connector. By plugging the connector element into the corresponding mating connector, a plug-in connection between the plug-in connector and the mating connector is established. In contrast, the at least one terminal connector is at least partly located in the interior of the cooling jacket. Thus, the terminal connector(s) can be exposed to a flow of coolant in the interior of the cooling jacket and heat deposited in the contact element can be removed. Furthermore, the at least one terminal connector may be electrically connected with one or more electrical wires that are led into the cooling jacket via one of the fluid ports. The electrical wires can be cooled by a flow of coolant in the cooling jacket as well. Preferably, at least one of the terminal connectors is implemented as a contact sleeve. A contact sleeve allows for accommodating and connecting an electrical wire. For establishing an electrical connection between the contact sleeve and the electrical wire, techniques like for example crimping, welding, screwing, clamping and others may be used. The contact sleeve may for example be implemented as a crimping sleeve or as an axial screw terminal.
- Preferably, the contact element comprises several terminal connectors, each of the several connectors being adapted for being electrically connected with an electrical wire. The contact element may either comprise a single terminal connector, but it may as well comprise several terminal connectors.
- Preferably, the interior of the cooling jacket is adapted for being pressurised by a fluid supplied via at least one of the fluid ports. The cooling jacket may for example be hermetically sealed. In case fluid is supplied to the cooling jacket, the cooling jacket can be pressurised by the flow of coolant provided via at least one of the fluid ports. Thus, a flow of coolant can be conveyed through the cooling jacket.
- Preferably, the terminal connector does not comprise any additional conduits or channels for increasing the interaction between the coolant and the terminal connector. Preferably, the terminal connector does not comprise a dedicated channel for conveying coolant through the terminal connector. It has been found that for an effective cooling operation, the flow resistance within the cooling jacket has to be kept low. For removing the heat deposited in the terminal connector, it is not necessary to provide for additional conduits and channels traversing the terminal connectors. A sheath flow encompassing the terminal connectors is sufficient.
- Preferably, via the second fluid port, a flow of coolant is supplied to the cooling jacket, and via the first fluid port, a flow of coolant is withdrawn from the cooling jacket. Preferably, the flow of coolant is supplied via the second fluid port, which is preferably located at a lateral position of the cooling jacket. The flow of fluid is directly supplied to the at least one connector terminal, which provides for an effective cooling.
- Preferably, the coolant is a gas or a liquid. As the cooling jacket is fluid-tightly sealed, it is also possible to pass a gas through the cooling jacket.
- Preferably, the second fluid port is disposed at a lateral position of the cooling jacket, wherein the at least one terminal connector is arranged such that a flow of coolant supplied via the second fluid port impinges on the at least one terminal connector or on an insulating sheath enclosing the at least one terminal connector. Further preferably, the second fluid port is located at a lateral position close to the connector element. By moving the point where the coolant is supplied towards the anterior part of the plug-in connector, i e in the direction towards the point where the connector element contacts a mating connector, the flow path for the flow of coolant is extended and cooling performance is improved.
- Preferably, the plug-in connector further comprises the at least one electrical wire, with each of the electrical wires being electrically connected with a corresponding terminal connector, wherein the at least one electrical wire and at least the part of the contact element that is exposed to a coolant supplied via at least one of the fluid ports are insulated relative to the coolant. In case both the electrical wires and the exposed parts of the contact elements are insulated relative to the coolant, the coolant does not get in direct contact with the current carrying elements. Accordingly, an electrically conductive coolant like for example water may be used.
- Preferably, the at least one electrical wire is enclosed by a cable insulation. Preferably, the plug-in connector further comprises an insulating sheath configured for electrically insulating the contact element relative to a coolant in the interior of the cooling jacket. By providing an insulating sheath, the current carrying parts can be electrically insulated relative to the coolant, thereby reducing safety hazards. Preferably, at least the part of the contact element that is exposed to a coolant supplied via at least one of the fluid ports is insulated with an insulating sheath. Preferably, the insulating sheath is integrally formed with the cooling jacket. Forming the cooling jacket and the insulating sheath in one piece provides for a reliable insulation. Alternatively, the insulating sheath may be implemented as a separate part. Preferably, the insulating sheath overlaps with the cable insulation. Preferably, the coolant is an electrically conductive coolant.
- Preferably, the plug-in connector further comprises the first tube, said first tube being fluid-tightly connected with the first fluid port. Preferably, the first tube is used for withdrawing coolant from the cooling jacket. Preferably, the plug-in connector further comprises the second tube, said second tube being fluid-tightly connected with the second fluid port. Preferably, the second tube is used for supplying coolant to the cooling jacket. Preferably, the cooling jacket is configured for receiving a flow of coolant via the second tube, for conveying the coolant through the cooling jacket's interior and for supplying the flow of coolant to the first tube.
- Preferably, the plug-in connector further comprises the at least one electrical wire, with each of the electrical wires being electrically connected with a corresponding terminal connector. Preferably, the at least one electrical wire is led into the cooling jacket via the first fluid port. By introducing the at least one electrical wire into the cooling jacket via one of the fluid ports, no additional cable passage is required. Preferably, the at least one electrical wire is encompassed by the first tube. The cable comprising one or more electrical wires is arranged within one of the first or the second tube and is led into the cooling jacket via one of the fluid ports. The at least one electrical wire may for example be enclosed by a flow of coolant, and accordingly, the cable is effectively cooled. The interspace between the electrical cable and the first tube may for example provide a fluid conduit for the flow of coolant. Alternatively, a dedicated channel for the coolant may for example be provided in the first tube.
- Preferably, the at least one electrical wire is encompassed by the first tube, with an interspace for conducting a flow of coolant being formed between the at least one electrical wire and the first tube. Preferably, a flow of coolant flowing in the interspace provides for a cooling of the at least one electrical wire enclosed by the first tube. The flow of coolant may for example encompass the at least one electrical wire at all sides, which allows for an effective transfer of heat.
- Preferably, the first fluid port is implemented as a connecting sleeve. Further preferably, the first fluid port is implemented as a connecting sleeve configured for circumferentially encompassing the first tube. Preferably, the second fluid port is implemented as a connecting sleeve. Further preferably, the second fluid port is implemented as a connecting sleeve configured for circumferentially encompassing the second tube. Preferably, the first fluid port and the second fluid port are implemented as separate fluid ports. Preferably, the first fluid port and the second fluid port are implemented as separate connecting sleeves. Further preferably, the first fluid port and the second fluid port are spaced apart from one another.
- Preferably, the plug-in connector further comprises a fastening ring adapted for fluid-tightly pressing the first fluid port against the first tube disposed in the first connecting sleeve. Preferably, the plug-in connector further comprises a fastening ring adapted for fluid-tightly pressing the second fluid port against the second tube disposed in the second connecting sleeve. Preferably, the plug-in connector further comprises a fastening ring adapted for fluid-tightly pressing the connecting sleeve against the central section of the contact element. Further preferably, a joining technique like crimping or flanging may for example be used for fluid-tightly pressing the connecting sleeve against the central section of the contact element.
- Preferably, the plug-in connector further comprises a second contact element, with the cooling jacket further comprising a second connecting sleeve for accommodating the second contact element, with an outer surface of the second contact element being encompassed by the second connecting sleeve in a fluid-tight manner. The cooling jacket can be used for cooling two or more contact elements. For example, the cooling jacket may comprise two or more connecting sleeves for accommodating the contact elements.
- Preferably, the second contact element comprises a second connector element and at least one second terminal connector, wherein the second connector element is at least partly exposed to the outside of the cooling jacket and wherein the at least one second terminal connector is at least partly disposed in the interior of the cooling jacket.
- Preferably, the plug-in connector is a charging connector adapted for performing a charging operation. In a charging operation, and in particular in a fast charging operation, large currents are supplied to an electric vehicle. The larger the current, the more heat will be dissipated. The cooling jacket allows to establish a thermal contact between the terminal connectors and the coolant and accordingly, the large amount of heat dissipated during the charging operation can be discharged.
- Preferably, the plug-in connector is configured for carrying an electrical current above 80 Ampere. Preferably, the charging connector is adapted for being connected with a charge port of an electric vehicle. Preferably, the mating direction when plugging the charging connector into a charge port is an axial direction of the charging connector.
- The following embodiments relate to a plug-in connector comprising a cooling jacket manufactured in one piece, the cooling jacket being made of a polymeric material.
- Preferably, at least part of the at least one terminal connector is exposed to a coolant supplied via at least one of the fluid ports. Preferably, in case a flow of coolant is supplied to at least one of the fluid ports, the coolant is in direct contact with the at least one terminal connector of the contact element. In case the coolant is in direct contact with at least one of the terminal connectors, the transfer of heat from the at least one terminal connector to the coolant is intensified.
- Preferably, the coolant is a non-conductive coolant. In general, cooling is required for plug-in connectors that carry large currents. In case of a direct contact between the coolant and the contact elements, a non-conductive coolant like for example oil is used, in order to avoid safety hazards.
- Preferably, in case a flow of coolant is supplied to the second fluid port, at least one of the terminal connectors is encompassed by a sheath flow of coolant. The sheath flow may for example enclose the terminal connector at all sides and may flow along the entire length of the terminal connector, thereby removing heat deposited in the contact element. A sheath flow of coolant provides for an effective removal of heat without unduly increasing flow resistance.
- The following embodiments relate to a plug-in connector comprising an insulating sheath configured for electrically insulating the contact element relative to a coolant in the interior of the cooling jacket.
- Preferably, the insulating sheath is integrally formed with the cooling jacket. Forming the cooling jacket and the insulating sheath in one piece provides a most reliable electrical insulation. Alternatively, the insulating sheath may be implemented as a separate part.
- Preferably, the cooling jacket is made of a rigid material. In this case, the cooling jacket stabilises the plug-in connector and provides a rigid support. No additional support is required. Further preferably, the cooling jacket is made of a polymeric material. Further preferably, the cooling jacket is made of hard plastic or of metal.
- Preferably, the cooling jacket is made of two or more parts. Providing a cooling jacket made of two or more parts may simplify the assembly, because the parts may be fitted from different directions.
- The invention is illustrated in greater detail with the aid of schematic drawings.
- It shows schematically:
-
Figure 1: Figure 1 shows a first example of a plug-in connector that provides for a direct cooling of the terminal connector and the electrical wire. -
Figure 2: Figure 2 shows a longitudinal section of the cooling jacket. -
Figure 3: Figure 3 shows a second example of a plug-in connector, wherein the current carrying parts are electrically insulated relative to the coolant. -
Figure 4: Figure 4 shows a third example of a plug-in connector, wherein the current carrying parts are electrically insulated relative to the coolant. - In the following description of preferred embodiments of the present invention, identical reference numerals denote identical or comparable components.
-
Figure 1 shows a longitudinal section of a plug-in connector 1. The plug-in connector 1 shown infigure 1 is particularly suited for carrying large electrical currents. The plug-in connector 1 may for example be a charging connector for a fast-charging vehicle charger, but it may as well be used for other applications where large electrical currents of for example 80 Ampere or more occur. In general, the higher the current flow in a conductor, the more heat will be deposited in the conductor. In order to remove the dissipated heat, the plug-in connector 1 comprises a cooling circuit configured for conveying a flow of coolant through the plug-in connector 1. - The plug-in connector 1 comprises a
contact element 2 made of conductive material, preferably metal. When viewed in theaxial direction 3 of the plug-in connector 1, thecontact element 2 comprises aconnector element 4, acentral section 5 and aterminal connector 6. Theconnector element 4 comprises aprotective pin 7 and splitfingers 8, with theconnector element 4 being configured for establishing a plug-in connection with a mating male connector, for example with a charge port of an electric vehicle. The mating direction for establishing the plug-in connection between theconnector element 4 and the mating male connector corresponds to theaxial direction 3 indicated infigure 1 . - For implementing a cooling circuit, the plug-in connector 1 shown in
figure 1 comprises acooling jacket 9 made of a polymeric material, preferably of an elastomer. When viewed in theaxial direction 3, the coolingjacket 9 comprises a connectingsleeve 10 at a first end. The connectingsleeve 10 is configured for accommodating thecentral section 5 of thecontact element 2. Thecontact element 2 is partly exposed to the outside of the coolingjacket 9 and partly disposed inside of the coolingjacket 9. For example, infigure 1 , theconnector element 4 is located outside of the coolingjacket 9, whereas theterminal connector 6 is located in the interior of the coolingjacket 9. Thecentral section 5 is integrally formed with theconnector element 4 and with theterminal connector 6. Preferably, thecontact element 2 is manufactured as a single piece, preferably as a rotationally symmetric piece. Alternatively, theconnector element 4, thecentral section 5 and theterminal connector 6 may be manufactured as separate parts, which are then mechanically and electrically connected. - The
central section 5 preferably has an essentially cylindrical shape, with the outer surface being circumferentially enclosed by the connectingsleeve 10. Due to the elastic properties of the coolingjacket 9, a fluid-tight sealing between the connectingsleeve 10 and thecentral section 5 can be obtained by pressing the connectingsleeve 10 against thecentral section 5. For example, as shown infigure 1 , afastening ring 11 that encloses both thecentral section 5 and the connectingsleeve 10 can be used for circumferentially pressing the connectingsleeve 10 against thecentral section 5, thereby establishing a fluid-tight connection. Alternatively, joining techniques like for example crimping or flanging can be employed for establishing a fluid-tight connection between thecentral section 5 and the connectingsleeve 10. In case a coolingjacket 9 with sufficient elasticity is used, no additional sealing gaskets or O-ring seals are required. - The
terminal connector 6 is located in the interior of the coolingjacket 9 and is configured for establishing an electrical connection with anelectrical wire 12. Theterminal connector 6 may for example be implemented as a contact sleeve configured for accommodating theelectrical wire 12. In particular, theelectrical wire 12 is inserted into the contact sleeve and fastened in the contact sleeve. For example, the electrical wire may be fixed in the contact sleeve by means of screws, clamps, crimping, welding, in particular ultrasonic welding or resistance welding, etc. For example, for applications in the field of fast charging, theelectrical wire 12 may for example carry a current of 80 Ampere or more, and accordingly, it is important to establish a reliable electrical connection of low contact resistance between theterminal connector 6 and theelectrical wire 12. - The cooling
jacket 9 is adapted for realising a cooling circuit for cooling both theterminal connector 6 and theelectrical wire 12. In addition to the connectingsleeve 10, which is disposed at a first end in theaxial direction 3, the coolingjacket 9 further comprises twofluid ports axial direction 3, the firstfluid port 13 is located at a second end of the coolingjacket 9, opposite to the connectingsleeve 10. Thesecond fluid port 14 is located at a lateral position of the coolingjacket 9, with thesecond fluid port 14 being connected via atubing 15 with alateral inlet 16 that branches off laterally from the axial flow path of the coolingjacket 9. - In
figure 2 , the coolingjacket 9 is shown separately. The coolingjacket 9 is manufactured in one piece and comprises three openings. At a first end in theaxial direction 3, the connectingsleeve 10 is arranged. At a second end opposite to the first end in theaxial direction 3, the firstfluid port 13 is disposed, and at a lateral position thereto, thesecond fluid port 14 is arranged, thesecond fluid port 14 being fluidically connected via thetubing 15 with thelateral inlet 16. - Via the first
fluid port 13, theelectrical wire 12 is inserted into theterminal connector 6. Furthermore, the firstfluid port 13 is configured for establishing a fluidic connection with afirst tube 17. For establishing the fluid-tight connection, thefirst tube 17 is inserted into the firstfluid port 13 in a way that the firstfluid port 13 encompasses the end of thefirst tube 17. Then, the firstfluid port 13, which may be implemented as a connecting sleeve, is circumferentially pressed against the end of thefirst tube 17. For example, the firstfluid port 13 may be pressed against thefirst tube 17 by means of afastening ring 18 to provide for a fluid-tight sealing. Thefirst tube 17 encloses theelectrical wire 12 in a way that aninterspace 19 is formed between thefirst tube 17 and theelectrical wire 12. Via theinterspace 19, a flow of coolant can be withdrawn from the interior of the coolingjacket 9. Thus, thefirst tube 17 encompasses theelectrical wire 12, with coolant being conducted in theinterspace 19 between theelectrical wire 12 and thefirst tube 17. - Furthermore, via the
second fluid port 14, a fluidic connection with thesecond tube 20 can be set up. For this purpose, the end of thesecond tube 20 is inserted into thesecond fluid port 14, which may be implemented as a connecting sleeve. In order to establish a fluid-tight connection, thefluid port 14 is circumferentially pressed against the end of thesecond tube 20. Preferably, afastening ring 21 is used for fixing thesecond tube 20. Furthermore, joining techniques like crimping and flanging may be used for establishing a fluid-tight connection. In case a coolingjacket 9 with sufficient elasticity is used, no extra sealing gasket or O-ring is required at the firstfluid port 13 and thesecond fluid port 14. - Via the
second tube 20, a flow of coolant is provided to thecooling jacket 9. As indicated by thearrows 22, the incoming flow of coolant is conveyed by atubing 15 to thelateral inlet 16 and impinges on theterminal connector 6. Theterminal connector 6 is in direct contact with the coolant, thus providing for an effective transfer of heat from thecontact element 2 to the coolant. This direct cooling effectively removes heat deposited in theterminal connector 6 and in thecontact element 2. At theterminal connector 6, the flow of coolant is redirected and, as indicated by thearrows 22, along the entire length of the terminal connector 6 a sheath flow is formed. The flow of coolant is injected into theinterspace 19 between theelectrical wire 12 and thefirst tube 17 and flows along theelectrical wire 12. Thus, the flow of coolant encompasses theelectrical wire 12 and provides for an effective cooling of theelectrical wire 12. Inside the coolingjacket 9, the coolant is in immediate contact with theterminal connector 6, which is made of conductive material. Accordingly, a non-conductive coolant like for example oil or gas should be used. - In order to avoid a deformation of the
first tube 17 and of thesecond tube 20, rigid supporting rings may be inserted inside thetubes fluid port 13 and thesecond fluid port 14. The connecting sleeves of thefluid ports figure 1 . The plug-in connector 1 shown infigure 1 further comprises arigid housing 23 that encompasses at least a part of the coolingjacket 9. The interior of the coolingjacket 9 is fluid-tightly sealed and can therefore be pressurised by a coolant supplied via at least one of thefluid ports jacket 9 may bulge out. In order to limit this deformation of the coolingjacket 9, the coolingjacket 9 is preferably encompassed by therigid housing 23. - For mounting the plug-in connector 1, the cooling
jacket 9 is slid on thefirst tube 17 in the direction to the right offigure 1 . The coolingjacket 9 is moved so far to the right that theelectrical wire 12 can be electrically connected with theterminal connector 6 of thecontact element 2. The electrical connection may for example be established by one of screwing, clamping, welding, crimping, etc. Then, the coolingjacket 9 is moved in the direction to the left offigure 1 , wherein thecentral section 5 of thecontact element 2 is inserted into the connectingsleeve 10 of the coolingjacket 9. Now, the firstfluid port 13 is in its final position relative to thefirst tube 17. The connectingsleeve 10 is fixed relative to thecentral section 5 by thefastening ring 11 and the firstfluid port 13 is fixed relative to thefirst tube 17 by thefastening ring 18. Then, thesecond tube 20 is slid into thesecond fluid port 14 and thesecond fluid port 14 is fixed relative to thesecond tube 20 by thefastening ring 21. - In
figure 3 , a further example of a plug-inconnector 24 is depicted. The plug-inconnector 24 comprises a cooling circuit for removing heat that has been dissipated in the conductor. However, in the embodiment offigure 3 , the electrical parts that may carry large electrical currents are electrically insulated relative to the coolant. The plug-inconnector 24 comprises acontact element 25 made of an electrically conductive material, preferably of metal. Thecontact element 25 comprises aconnector element 26, acentral section 27 and aterminal connector 28. In the example offigure 3 , theconnector element 26 comprises a socket with alamellae basket 29. Theconnector element 26 is configured for establishing an electric contact with a mating male connector when the plug-inconnector 24 is connected with the mating male connector, with the mating direction being theaxial direction 30 indicated infigure 3 . - For realising a cooling circuit, the plug-in
connector 24 comprises a coolingjacket 31 made of a polymeric material, preferably of an elastomer. The coolingjacket 31 comprises a connectingsleeve 32, a firstfluid port 33 and a secondfluid port 34. When viewed in theaxial direction 30, the connectingsleeve 32 is located at a first end, whereas the firstfluid port 33 is disposed at a second end opposite to the first end. Thesecond fluid port 34 is located at a lateral position of the coolingjacket 31. - The connecting
sleeve 32 is configured for accommodating thecentral section 27 of thecontact element 25. For establishing a fluid-tight connection, the connectingsleeve 32 is circumferentially pressed against thecentral section 27. For example, afastening ring 35 may be employed for establishing a fluid-tight seal, but other joining techniques like crimping or flanging can be used as well. In case the connectingsleeve 32 is made of an elastomer, no extra sealing gaskets or O-rings are required. After thecentral section 27 has been fixed by the connectingsleeve 32, theconnector element 26 is at least partly exposed to the outside of the coolingjacket 31, whereas theterminal connector 28 is at least partly located inside the coolingjacket 31. Theterminal connector 28, which may for example be implemented as a contact sleeve, is configured for establishing an electrical connection with theelectrical wire 36. For establishing this electrical connection, theelectrical wire 36 is inserted via the firstfluid port 33 into the interior of the coolingjacket 31 and fastened in theterminal connector 28. - In the example of
figure 3 , both theterminal connector 28 and theelectrical wire 36 are electrically insulated relative to the coolant flowing in the coolingjacket 31. Theelectrical wire 36 is equipped with acable insulation 37. In the interior of the coolingjacket 31, an insulatingsheath 38 is provided, said insulatingsheath 38 being integrally formed with the coolingjacket 31. Alternatively, the insulating sheath may be realised as a separate part. The insulatingsheath 38 covers and insulates theterminal connector 28 and overlaps with thecable insulation 37 of theelectrical wire 36. Afastening ring 39 may be used for pressing the insulatingsheath 38 against thecable insulation 37 of theelectrical wire 36. Alternatively, joining techniques like crimping or flanging can be used for fixing the electrical insulation. As a result, all current carrying parts are electrically insulated relative to the coolant flowing in the coolingjacket 31. - The first
fluid port 33 of the coolingjacket 31 is configured for establishing a fluidic connection with afirst tube 40. As shown infigure 3 , theelectrical wire 36 is enclosed by thefirst tube 40 and aninterspace 41 is formed between thecable insulation 37 and thefirst tube 40. At the end of thefirst tube 40, aspacer ring 42 is inserted between thecable insulation 37 and thefirst tube 40. Via thespacer ring 42, a flow of coolant can be injected into theinterspace 41 and withdrawn from the coolingjacket 31. For establishing a fluid-tight connection with the coolingjacket 31, the coolingjacket 31 with theelectrical wire 36 is slid onto thefirst tube 40. Then, the firstfluid port 33, which may for example be realised as a connecting sleeve, is circumferentially pressed against thefirst tube 40 and thespacer ring 42. Afastening ring 43 may be used for securing a fluid-tight connection or a joining technique like crimping or flanging may be employed. In case the firstfluid port 33 is made of an elastomer, no extra sealing gaskets or O-rings are required. - The
second fluid port 34 is adapted for accommodating thesecond tube 44. For establishing a fluid-tight connection, thesecond tube 44 is inserted into thesecond fluid port 34 and the fluid-tight connection is fastened by afastening ring 45. The coolingjacket 31 is adapted for realising a cooling circuit for cooling both theterminal connector 28 and theelectrical wire 36. During the operation of the plug-inconnector 24, a flow of coolant is supplied to thesecond fluid port 34 via thesecond tube 44, as indicated byarrow 46. The flow of coolant impinges on the insulatingsheath 38, thereby effecting a cooling of theterminal connector 28 and theelectrical wire 36. The flow of coolant is redirected as indicated byarrow 47. Via the passageways of thespacer ring 42, the flow of fluid is injected into theinterspace 41, thereby cooling theelectrical wire 36. - As the cooling
jacket 31 is fluid-tightly sealed, it can be pressurised by a coolant supplied via an at least one of thefluid ports jacket 31, the coolingjacket 31 is preferably encompassed by a rigid housing, which is not shown infigure 3 . -
Figure 4 shows another embodiment of a plug-inconnector 48, with said plug-inconnector 48 comprising a cooling circuit for removing heat that has been deposited in the plug-in connector. The plug-inconnector 48 comprises acontact element 49 with aconnector element 50, acentral section 51 and aterminal connector 52, wherein theterminal connector 52 is configured for establishing an electric connection with theelectrical wire 53. The plug-inconnector 48 further comprises a coolingjacket 54 that provides fluidic pathways for cooling theterminal connector 52 and theelectric wire 53. The coolingjacket 54 is made of a rigid material. Preferably, the coolingjacket 54 is made of hard plastic or of metal. - The cooling
jacket 54 comprises a connectingsleeve 56, the connectingsleeve 56 being disposed at a first end of the plug-inconnector 48 in theaxial direction 55. The connectingsleeve 56 is configured for accommodating thecontact element 49 and for circumferentially enclosing thecentral section 51 of thecontact element 49 in a fluid-tight manner. At the opposite end of the coolingjacket 54 viewed in theaxial direction 55, a firstfluid port 57 is arranged. The firstfluid port 57 is configured for establishing a fluidic connection with afirst tube 58. The coolingjacket 54 further comprises a secondfluid port 59, thesecond fluid port 59 being fluidically connected with aninlet 60 disposed at a lateral position of the coolingjacket 54. Thesecond fluid port 59 is adapted for establishing a fluidic connection with asecond tube 61. - In the embodiment of
figure 4 , the electrically conductive parts located inside the coolingjacket 54 are insulated relative to the coolant. Theelectrical wire 53 is provided with acable insulation 62 and theterminal connector 52 is enclosed by an insulatingsheath 63. In the region where theinsulation sheath 63 overlaps with thecable insulation 62, the insulatingsheath 63 is circumferentially pressed against thecable insulation 62 by afastening ring 64. Accordingly, both theelectrical wire 53 and theterminal connector 52 are insulated relative to the coolant. When conveying a flow of coolant in the direction of thearrows 65 from thesecond tube 61 via thesecond fluid port 59 to the coolingjacket 54, the flow of coolant impinges on the insulatingsheath 63, but in contrast to the embodiment offigure 1 there is no direct contact between the coolant and theterminal connector 52. Accordingly, the flow of coolant conveyed through the coolingjacket 54 provides for an indirect cooling of theterminal connector 52 and theelectrical wire 53. Both a conductive coolant and a non-conductive coolant can be used. - The
first tube 58 encompasses theelectrical wire 53, whereby aninterspace 66 is formed between thecable insulation 62 and thefirst tube 58. At the end of thefirst tube 58 thespacer ring 68 is inserted between thecable insulation 62 and thefirst tube 58. Via thespacer ring 68, a flow of coolant can be injected into theinterspace 66 and withdrawn from the coolingjacket 54. - For mounting the plug-in
connector 48, theelectrical wire 53 is connected with theterminal connector 52 and the insulatingsheath 63 is disposed around theterminal connector 52 and overlaps with thecable insulation 62. Then, the coolingjacket 54 and a sealingring 69 positioned in therecess 67 are slid onto thecontact element 49. Finally, acap 70 is attached to the firstfluid port 57. Thecap 70 may for example be attached to the firstfluid port 57 using a flanging tool. Thesecond tube 61 is attached to thesecond fluid port 59 and fixed by afastening ring 71. - During operation of the plug-in
connector 48, a flow of coolant is conveyed from thesecond tube 61 via thesecond fluid port 59 to the interior of the coolingjacket 54. Along theterminal connector 52, a sheath flow of coolant is established. The coolant is then injected into theinterspace 66 between thecable insulation 62 and thefirst tube 58. - The features described in the above description, claims and figures can be relevant to the invention in any combination. Their reference numerals in the claims have merely been introduced to facilitate reading of the claims. They are by no means meant to be limiting.
-
- 1
- plug-in connector
- 2
- contact element
- 3
- axial direction
- 4
- connector element
- 5
- central section
- 6
- terminal connector
- 7
- protective pin
- 8
- split fingers
- 9
- cooling jacket
- 10
- connecting sleeve
- 11
- fastening ring
- 12
- electrical wire
- 13
- first fluid port
- 14
- second fluid port
- 15
- tubing
- 16
- lateral inlet
- 17
- first tube
- 18
- fastening ring
- 19
- interspace
- 20
- second tube
- 21
- fastening ring
- 22
- arrows
- 23
- housing
- 24
- plug-in connector
- 25
- contact element
- 26
- connector element
- 27
- central section
- 28
- terminal connector
- 29
- lamellae basket
- 30
- axial direction
- 31
- cooling jacket
- 32
- connecting sleeve
- 33
- first fluid port
- 34
- second fluid port
- 35
- fastening ring
- 36
- electrical wire
- 37
- cable insulation
- 38
- insulating sheath
- 39
- fastening ring
- 40
- first tube
- 41
- interspace
- 42
- spacer ring
- 43
- fastening ring
- 44
- second tube
- 45
- fastening ring
- 46
- arrow
- 47
- arrow
- 48
- plug-in connector
- 49
- contact element
- 50
- connector element
- 51
- central section
- 52
- terminal connector
- 53
- electrical wire
- 54
- cooling jacket
- 55
- axial direction
- 56
- connecting sleeve
- 57
- first fluid port
- 58
- first tube
- 59
- second fluid port
- 60
- inlet
- 61
- second tube
- 62
- cable insulation
- 63
- insulating sheath
- 64
- fastening ring
- 65
- arrows
- 66
- interspace
- 67
- recess
- 68
- spacer ring
- 69
- sealing ring
- 70
- cap
- 71
- fastening ring
Claims (15)
- A plug-in connector (1, 24), the plug-in connector comprising
a contact element (2, 25) with a connector element (4, 26) and at least one terminal connector (6, 28),
a cooling jacket (9, 31) with a first fluid port (13, 33) adapted for fluidically connecting the cooling jacket (9, 31) with a first tube (17, 40) and a second fluid port (14, 34) adapted for fluidically connecting the cooling jacket (9, 31) with a second tube (20, 44), characterised in that
the cooling jacket (9, 31) further comprises a connecting sleeve (10, 32) for accommodating the contact element (2, 25), wherein the cooling jacket (9, 31) is manufactured in one piece and wherein the cooling jacket (9, 31) is made of a polymeric material,
wherein an outer surface of the contact element (2, 25) is encompassed by the connecting sleeve (10, 32) in a fluid-tight manner, wherein the connector element (4, 26) is at least partly exposed to the outside of the cooling jacket (9, 31) and wherein the at least one terminal connector (6, 28) is at least partly disposed in the interior of the cooling jacket (9, 31), wherein the at least one terminal connector (6, 28) is configured for being electrically connected with at least one electrical wire (12, 36) that is introducible into the cooling jacket (9, 31) via at least one of the fluid ports. - Plug-in connector (1, 24) according to claim 1, wherein the cooling jacket (9, 31) is made of an elastomer.
- Plug-in connector (1) according to claim 1 or claim 2, further comprising a housing (23), said housing (23) encompassing the cooling jacket (9), wherein a support provided by the housing (23) is adapted for limiting a deformation or expansion of the cooling jacket (9).
- Plug-in connector (1, 24) according to any one of claims 1 to 3, wherein the connecting sleeve (10, 32) is disposed at a first end in an axial direction (3, 30) of the plug-in connector (1, 24), wherein the first fluid port (13, 33) is disposed at a second end opposite to the first end in the axial direction (3, 30) and wherein the second fluid port (14, 34) is disposed at a lateral position of the cooling jacket (9, 31).
- Plug-in connector (1, 24) according to any one of claims 1 to 4, wherein the interior of the cooling jacket (9, 31) is adapted for being pressurised by a fluid supplied via at least one of the fluid ports.
- Plug-in connector (1, 24) according to any one of claims 1 to 5, wherein via the second fluid port (14, 34), a flow of coolant is supplied to the cooling jacket (9, 31), and wherein via the first fluid port (13, 33), a flow of coolant is withdrawn from the cooling jacket (9, 31).
- Plug-in connector (1, 24) according to any one of claims 1 to 6, wherein the second fluid port (14, 34) is disposed at a lateral position of the cooling jacket (9, 31), wherein the at least one terminal connector (6, 28) is arranged such that a flow of coolant supplied via the second fluid port (14, 34) impinges on the at least one terminal connector (6) or on an insulating sheath (38) enclosing the at least one terminal connector (28).
- Plug-in connector (1) according to any one of claims 1 to 7, wherein in case a flow of coolant is supplied to at least one of the fluid ports, the coolant is in direct contact with the at least one terminal connector (6) of the contact element (2).
- Plug-in connector (1) according to claim 8, wherein the coolant is a non-conductive coolant.
- Plug-in connector (24) according to any one of claims 1 to 7, further comprising the at least one electrical wire (36), with each of the electrical wires (36) being electrically connected with a corresponding terminal connector (28), wherein the at least one electrical wire (36) and at least the part of the contact element (25) that is exposed to a coolant supplied via at least one of the fluid ports are electrically insulated relative to the coolant.
- Plug-in connector (1, 24) according to any one of claims 1 to 10, wherein the plug-in connector (1, 24) further comprises a second contact element, with the cooling jacket (9, 31) further comprising a second connecting sleeve for accommodating the second contact element, with an outer surface of the second contact element being encompassed by the second connecting sleeve in a fluid-tight manner.
- Plug-in connector (1, 24) according to any one of claims 1 to 11, wherein the plug-in connector (1, 24) is a charging connector adapted for performing a charging operation.
- A method for operating a plug-in connector (1, 24), the plug-in connector comprising a contact element (2, 25) with a connector element (4, 26) and at least one terminal connector (6, 28),
a cooling jacket (9, 31) with a connecting sleeve (10, 32) for accommodating the contact element (2, 25), a first fluid port (13, 33) adapted for fluidically connecting the cooling jacket (9, 31) with a first tube (17, 40) and a second fluid port (14, 34) adapted for fluidically connecting the cooling jacket (9, 31) with a second tube (20, 44), wherein the cooling jacket (9, 31) is manufactured in one piece and wherein the cooling jacket (9, 31) is made of a polymeric material,
wherein an outer surface of the contact element (2, 25) is encompassed by the connecting sleeve (10, 32) in a fluid-tight manner, wherein the connector element (4, 26) is at least partly exposed to the outside of the cooling jacket (9, 31) and wherein the at least one terminal connector (6, 28) is at least partly disposed in the interior of the cooling jacket (9, 31), wherein the at least one terminal connector (6, 28) is configured for being electrically connected with at least one electrical wire (12, 36) that is introducible into the cooling jacket (9, 31) via at least one of the fluid ports,
the method comprising
supplying a flow of coolant to the second fluid port (14, 34),
wherein the coolant passes the cooling jacket's interior, with the coolant impinging on the at least one terminal connector (6) of the contact element (2) or on an insulating sheath (38) enclosing the at least one terminal connector (28),
withdrawing a flow of coolant at the first fluid port (13, 33). - A plug-in connector (24, 48), the plug-in connector comprising a contact element (25, 49) with a connector element (26, 50) and at least one terminal connector (28, 52),
a cooling jacket (31, 54) with a first fluid port (33, 57) adapted for fluidically connecting the cooling jacket (31, 54) with a first tube (40, 58) and a second fluid port (34, 59) adapted for fluidically connecting the cooling jacket (31, 54) with a second tube (44, 61), characterised in that
the cooling jacket (31, 54) further comprises a connecting sleeve (32, 56) for accommodating the contact element (25, 49),
wherein an outer surface of the contact element (25, 49) is encompassed by the connecting sleeve (32, 56) in a fluid-tight manner, wherein the connector element (26, 50) is at least partly exposed to the outside of the cooling jacket (31, 54) and wherein the at least one terminal connector (28, 52) is at least partly disposed in the interior of the cooling jacket (31, 54), wherein the at least one terminal connector (28, 52) is configured for being electrically connected with at least one electrical wire (36, 53) that is introducible into the cooling jacket (31, 54) via at least one of the fluid ports,
the plug-in connector (24, 48) further comprising an insulating sheath (38, 63) configured for electrically insulating the contact element (25,49) relative to a coolant in the interior of the cooling jacket (31, 54). - A method for operating a plug-in connector (24, 48), the plug-in connector comprising a contact element (25, 49) with a connector element (26, 50) and at least one terminal connector (28, 52),
a cooling jacket (31, 54) with a connecting sleeve (32, 56) for accommodating the contact element (25, 49), a first fluid port (33, 57) adapted for fluidically connecting the cooling jacket (31, 54) with a first tube (40, 58) and a second fluid port (34, 59) adapted for fluidically connecting the cooling jacket (31, 54) with a second tube (44, 61), wherein an outer surface of the contact element (25, 49) is encompassed by the connecting sleeve (32, 56) in a fluid-tight manner, wherein the connector element (26, 50) is at least partly exposed to the outside of the cooling jacket (31, 54) and wherein the at least one terminal connector (28, 52) is at least partly disposed in the interior of the cooling jacket (31, 54), wherein the at least one terminal connector (28, 52) is configured for being electrically connected with at least one electrical wire (36, 53) that is introducible into the cooling jacket (31, 54) via at least one of the fluid ports,
the plug-in connector further comprising an insulating sheath (38, 63) configured for electrically insulating the contact element (25,49) relative to a coolant in the interior of the cooling jacket (31, 54),
the method comprising
supplying a flow of coolant to the second fluid port (34, 59),
wherein the coolant passes the cooling jacket's interior, with the coolant impinging on the insulating sheath (38, 63),
withdrawing a flow of coolant at the first fluid port (33, 57).
Priority Applications (1)
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EP17170805.0A EP3401955B1 (en) | 2017-05-12 | 2017-05-12 | Plug-in connector with a cooling jacket |
Applications Claiming Priority (1)
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EP17170805.0A EP3401955B1 (en) | 2017-05-12 | 2017-05-12 | Plug-in connector with a cooling jacket |
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EP3401955A1 true EP3401955A1 (en) | 2018-11-14 |
EP3401955B1 EP3401955B1 (en) | 2021-06-30 |
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EP17170805.0A Active EP3401955B1 (en) | 2017-05-12 | 2017-05-12 | Plug-in connector with a cooling jacket |
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FR3139958A1 (en) * | 2022-09-21 | 2024-03-22 | Hutchinson | Electric machine |
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FR3139958A1 (en) * | 2022-09-21 | 2024-03-22 | Hutchinson | Electric machine |
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